US7516634B1 - Electrohydraulic forming tool - Google Patents
Electrohydraulic forming tool Download PDFInfo
- Publication number
- US7516634B1 US7516634B1 US12/114,998 US11499808A US7516634B1 US 7516634 B1 US7516634 B1 US 7516634B1 US 11499808 A US11499808 A US 11499808A US 7516634 B1 US7516634 B1 US 7516634B1
- Authority
- US
- United States
- Prior art keywords
- spacer
- electrode
- electrodes
- vessel
- shaft
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/06—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure by shock waves
- B21D26/12—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure by shock waves initiated by spark discharge
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S72/00—Metal deforming
- Y10S72/707—Magnetism
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49803—Magnetically shaping
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/53448—Vehicle wheel
Definitions
- the present invention relates to an electrohydraulic forming (EHF) tool.
- EHF electrohydraulic forming
- Aluminum alloys and advanced high strength steels are becoming increasingly common as materials used in automotive body construction.
- One of the major barriers to wider implementation of these materials is their inherent lack of formability as compared to mild steels.
- Incorporating lightweight materials such as advanced high strength steels (AHSS) and aluminum alloys (AA) into high-volume automotive applications is critical to reducing vehicle weight, leading to improved fuel economy and reduced tailpipe emissions.
- stamping issues and the lack of intrinsic material formability in AHSS and AA are significant barriers to the implementation of lightweight materials into high-volume production.
- stamping challenges are associated with the implementation of AHSS and AA in automotive production.
- the primary method of stamping body panels and structural parts is forming sheet material between a sequence of two sided dies installed in a transfer press or a line of presses.
- DDQ Deep Drawing Quality
- EDDQ Extra Deep Drawing Quality
- the formability of aluminum alloys typically does not exceed 25%.
- stamping engineers do not intend to form sheet metal beyond a level of 15% in plane strain due to the much lower work-hardening modulus of metals in these strain ranges, and also due to the danger of local dry conditions on the blank surface.
- the formability of AHSS is typically around 30%. Insufficient formability drives the necessity to weld difficult to form panels from several parts or to increase the thickness of the blank used in forming the panels.
- Electrohydraulic forming is a process which can significantly increase sheet metal formability by forming a sheet metal blank into a female die at high strain rates.
- the high strain rate is achieved by taking advantage of the electrohydraulic effect, which can be described as the rapid discharge of electric current between electrodes submerged in water and the propagation through the water of the resulting shockwave—a complex phenomenon related to the discharge of high voltage electricity through a liquid.
- the shockwave in the liquid initiated by the expansion of the plasma channel formed between two electrodes upon discharge, is propagated towards the blank at high speed, and the mass and momentum of the water in the shockwave causes the blank to be deformed into an open die that has a forming surface.
- the shockwave forces the blank into engagement with the forming surface to form the metal blank into the desired shape.
- FIG. 1 schematically illustrates an EHF process
- FIG. 2 illustrates an electrode configuration in accordance with one non-limiting aspect of the present invention
- FIGS. 3-4 illustrate a spacer in accordance with one non-limiting aspect of the present invention
- FIGS. 5-6 illustrate an electrode configuration in accordance with one non-limiting aspect of the present invention
- FIG. 7 illustrates a configuration for arranging and combining pairs of electrodes in accordance with one non-limiting aspect of the present invention.
- FIG. 8 illustrates a paired electrode system in accordance with one non-limiting aspect of the present invention.
- FIG. 1 schematically illustrates the EHF process.
- Electrical energy may be stored in high voltage capacitors 220 with the assistance of a transformer 222 and a set of diodes 224 .
- a special switch or discharging device 226 such as an ignitron, vacuum discharger, or solid state switch, may be used to close the circuit and deliver high voltage stored in the capacitor 220 to electrodes 228 , 230 .
- the parameters which define the efficiency of the EHF process include the mutual position of the electrodes 228 , 230 , the electrical properties of the liquid, the charged voltage, the capacitance, the inductance and resistance of the equipment and connecting cables, the volume of the chamber, and the distance between the discharge channel and the blank.
- the electrical resistance of a channel between the electrodes 228 , 230 drops by several orders of magnitude, and the electric current sharply grows due to the increasing temperature and the expansion of the plasma channel. Due to the significant amount of electric energy pumped through the small, ionized channel, the temperature may increase, and the pressure inside the channel may grow during a short time interval. Driven by such high pressure, the discharge channel is quickly expanding and creates a shockwave.
- a blank 232 may be clamped between a chamber 234 and die cavity 236 , which defines a forming surface 237 agent which the blank 232 is pressed during forming.
- the outer edge of the part may have a three dimensional contour.
- a binder (not shown) having a corresponding shape can be employed to support the blank 232 .
- they should be electrically insulated from the chamber 234 , and the insulation material should be able to withstand the maximum voltage of the process.
- the repeated discharge of high-voltage electricity between the electrodes 228 , 230 can cause the electrodes 228 , 230 to gradually erode. This erosion can cause the distance between the electrodes 228 , 230 to grow slowly over time, which can have a negative effect on the efficiency of the EHF process, if the electrodes 228 , 230 are not adjusted and repositioned periodically. Due to the need to electrically insulate the electrodes 228 , 230 from the EHF chamber 234 , it can be difficult and cumbersome to adjust and reposition the electrodes 228 , 230 in an attempt to regain the desired spacing and efficiency.
- FIG. 2 illustrates an electrode configuration 10 in accordance with one non-limiting aspect of the present invention.
- a pair of electrodes 12 , 14 may include consumable electrode tips 16 , 18 at a leading end of a body portion 20 , 22 .
- the tips 16 , 18 can be replaced instead of replacing an entire solid rod forming the body portion 20 , 22 .
- the consumable electrode tips 16 , 18 may be threaded or press fit to the electrodes 12 , 14 .
- a polyurethane insulation layer or other resilient material 26 , 28 may be molded directly onto the body 20 , 22 .
- the body 20 , 22 may include an undulating outer surface with successive sections having different diameters. Some or all of the diameters may be larger than a diameter of resilient element. The diameter conflict may be sufficient to force the resilient material 26 , 28 to fill cavities within the undulated outer surface. This allows the resilient material to electrically isolate the electrode body 20 , 22 and to limit liquid from leaking out of the chamber 30 .
- the press-fit nature of the resilient material 26 , 28 allows the body 20 , 22 to be easily inserted and extracted through an electrode shaft or collar 40 , 42 attached to the chamber 30 .
- the electrode 12 , 14 can be removed or advanced into the chamber 30 .
- a spacer 44 can be positioned within the chamber 30 to facilitate advancing the electrodes 12 , 14 to the desired position.
- FIG. 3 illustrates the spacer 44 being located within a relief or other fixture 46 in the chamber
- FIG. 4 illustrates the spacer 44 being robotically positioned with an arm of a robot (not shown).
- the electrodes 12 , 14 can be advanced into contact. If the spacer 44 is positioned at a location that is beneficial to the efficiency of the electrical discharge, the advancement of the electrodes 12 , 14 in this manner allows the electrodes 12 , 14 to be positioned at a desirable location relative to each other.
- the electrodes 12 , 14 may be advanced manually and/or with a robot or other tool. The undulations on the electrodes 12 , 14 and the press-fit between the resilient element 26 , 28 and the collar 40 , 42 may require a certain amount of force be overcome before the electrodes 12 , 14 can be advanced.
- a nut 50 , 52 and compression ring 54 , 56 used to compress the resilient material 26 , 28 to the electrode body 20 , 22 and to seal the chamber 30 , can influence the amount of force needed to position the electrodes 12 , 14 .
- the nut 50 may be loosened from its normally tightened state to reduce this pressure.
- FIGS. 5-6 illustrate an electrode configuration 80 in accordance with one non-limiting aspect of the present invention.
- a chamber 82 shown in FIG. 6 is not angled in an upwardly sloping direction. While neither FIG. 2 nor 6 illustrate a blank and forming die, but either would be positioned over top of the chamber 82 or over top of a binder (not shown) positioned on top of the chamber.
- a pair of electrodes 84 , 86 having a tip 88 , 90 , body 92 , 94 , and shaft 96 , 98 are positioned within side openings of the chamber 82 .
- the electrodes 84 , 86 may be operated to discharge a shockwave within liquid to form a blank in the manner described above.
- a resilient element 102 , 104 may be positioned within the openings to seal the shaft 96 , 98 and limit liquid leakage.
- One or more seals 110 , 112 , 114 , 116 , 118 , 120 may be strategically positioned between compression points to help prevent leakage.
- a chamber fastener 124 , 126 may be press-fit, threadably secured, or otherwise fastened to a portion of the shaft 96 , 98 and operatively connected to press a portion of the resilient material 102 , 104 against an outside of the chamber 82 while securing a positioning on the shaft 96 , 98 with respect to chamber 82 .
- the outer diameter of the shaft 96 , 98 may include features that limit a distance by which it can advance into the chamber 82 . It may be advantageous to fix this distance, so that the shaft 96 , 98 is positioned at the same location each time it is removed and subsequently inserted into the openings. This can be helpful in facilitating proper positioning of the electrodes 84 , 86 .
- an outer diameter of the body 92 , 94 may be less than an inner diameter of the shaft 96 , 98 so that the body 92 , 94 can be completely removed from the chamber 82 without having to unfasten the shaft 96 , 98 .
- An end of the body 92 , 94 may be shaped to include a shoulder 130 , 132 that extends above an end of the shaft 96 , 98 .
- a body fastener 134 , 136 can be press-fit, threadably secured, or otherwise fastened over corresponding portions of the body 92 , 94 and shaft 96 , 98 .
- the fastener 134 , 136 may be tightened to press the shaft 92 , 94 and body 96 , 98 together.
- the seal 130 , 132 may be positioned between the shaft 92 , 94 and body 96 , 98 to help prevent leakage.
- the electrode tips 88 , 90 may be press-fit, threadably secured, or otherwise fastened to a leading end of the body 92 , 94 .
- the body 92 , 94 may include a shoulder portion 140 , 142 against which the tip 88 , 90 may be secured.
- the consumable tip 88 , 90 may be discarded and replaced with a new tip should corrosion or properties of the tip 88 , 90 degrade over time due to being continuously discharged within the liquid.
- the tips 88 , 90 may be easily replaced by unfastening the body fastener 134 , 136 and slidable removing the body 92 , 94 through the shaft 96 , 98 .
- FIG. 6 illustrate spacers 144 , 146 that may be positioned between the body 92 , 94 and shaft 96 , 98 and/or the body 92 , 94 and tip 88 , 90 .
- the spacers 144 , 146 may be shaped to fit over the body 92 , 94 and/or otherwise configured into some other type of shim.
- the object of the spacers 144 , 146 is to offset the body 92 , 94 and/or the tip 88 , 90 from the non-offset positions shown in FIG. 6 . This allows the present invention to initially position the electrodes 88 , 90 and then to adjust their positioning simply by adding and/or removing the spacers 144 , 146 . While only a single spacer 144 , 146 is shown to be included at each end of the body 92 , 94 , multiple spacers of any shape or thickness may be include at each end to facilitate positioning the electrodes 88 , 90 .
- FIG. 7 illustrates a configuration 170 for arranging and combining pairs of electrodes 172 , 174 , 176 , 178 , 180 , 182 .
- This arrangement essentially creates several small EHF chambers, each chamber complete with its own electrode pair.
- This arrangement could be attached to a single binder plate which would then serve as a large EHF chamber for forming large panels. Since the available forming pressure in a volume of water in the EHF process would decrease with increasing chamber volume, this reconfigurable and modular EHF arrangement allows for high forming pressures to be generated at all areas within the chamber volume.
- reconfigurable EHF chambers also present an opportunity for reducing capital costs spent on EHF tooling, since the same small chambers could be attached to many different binders and upper dies as necessary, i.e., multiple dies would be used with a single chamber at the same time. This allows for precise tailoring of the EHF process for a specific part, since certain parts may require more forming pressure in one area than in another.
- FIG. 8 illustrates a paired electrode system 190 in accordance with one non-limiting aspect of the present invention.
- This system 190 includes a first and second set of electrodes 192 , 194 .
- Each set of electrodes 192 , 194 may operate in the manner describe above.
- the sets 192 , 194 are orthogonally positioned with respect to each other so that the resulting shockwave produces substantially the same result regardless of whether it originates with the first or second set of electrodes 192 , 194 .
- the positioning of each set of electrodes 192 , 194 may be facilitated with the use of the above-described spacers.
- Each set of electrodes 192 , 194 may be positioned, so that either set 192 , 194 can be used to form a blank (not shown).
- the present invention contemplates an arrangement when one set of electrodes 192 is used until their performance degrades below an acceptable threshold. Once this threshold is met, the electric discharge can be switched over to the other set of electrodes 194 . This allows the present invention to switch the electrodes 192 , 194 without having to service the degraded electrodes until a later time when it may be more convenient to open the die. While the switched-in electrodes 194 are in use, the degraded electrodes 192 may optionally be removed for servicing.
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- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
Description
Claims (20)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US12/114,998 US7516634B1 (en) | 2008-05-05 | 2008-05-05 | Electrohydraulic forming tool |
CN2009201465918U CN201552234U (en) | 2008-05-05 | 2009-05-04 | Electro-hydraulic forming tool |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/114,998 US7516634B1 (en) | 2008-05-05 | 2008-05-05 | Electrohydraulic forming tool |
Publications (1)
Publication Number | Publication Date |
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US7516634B1 true US7516634B1 (en) | 2009-04-14 |
Family
ID=40525016
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/114,998 Expired - Fee Related US7516634B1 (en) | 2008-05-05 | 2008-05-05 | Electrohydraulic forming tool |
Country Status (2)
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US (1) | US7516634B1 (en) |
CN (1) | CN201552234U (en) |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090272167A1 (en) * | 2008-05-05 | 2009-11-05 | Ford Global Technologies, Llc | Pulsed electro-hydraulic calibration of stamped panels |
US20100154502A1 (en) * | 2008-12-19 | 2010-06-24 | Johnson-Morke Linda M | High velocity forming of medical device casings |
EP2292343A1 (en) * | 2009-09-04 | 2011-03-09 | Reinhold Thewes | Device for electrohydraulic sheet metal forming |
US20120111080A1 (en) * | 2010-11-05 | 2012-05-10 | Ford Global Technologies, Llc | Electrode assembly for electro-hydraulic forming process |
US20130283878A1 (en) * | 2012-04-05 | 2013-10-31 | The Ohio State University | Electrically driven rapidly vaporizing foils, wires and strips used for collision welding and sheet metal forming |
US8844331B2 (en) | 2010-10-29 | 2014-09-30 | Ford Global Technologies, Llc | Electro-hydraulic forming process with electrodes that advance within a fluid chamber toward a workpiece |
US9044801B2 (en) | 2013-10-21 | 2015-06-02 | Ford Global Technologies, Llc | Deep draw manufacturing process |
US11084122B2 (en) | 2017-07-13 | 2021-08-10 | Ohio State Innovation Foundation | Joining of dissimilar materials using impact welding |
US11389853B2 (en) * | 2019-12-18 | 2022-07-19 | Harbin Institute Of Technology | Device and method for forming metal plate by using high-energy electric pulse to drive energetic materials |
WO2024149611A1 (en) * | 2023-01-10 | 2024-07-18 | I-Rox | Pulsed high-power electric discharge firing tool |
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US8534107B2 (en) * | 2011-06-10 | 2013-09-17 | Ford Global Technologies, Llc | Method and apparatus for pulsed forming, punching and trimming of tubular members |
CN104785605B (en) * | 2015-03-31 | 2017-04-19 | 西北工业大学 | Electro-hydraulic forming device for pipe fitting and forming method |
CN105463162B (en) * | 2015-12-04 | 2017-12-15 | 南京航空航天大学 | A kind of electro-hydraulic intensifying device of hardware internal surface of hole and its intensifying method |
CN111604402A (en) * | 2019-02-26 | 2020-09-01 | 北京机电研究所有限公司 | Aluminum alloy sheet precise shaping method and device based on electro-hydraulic forming |
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